Responsive insoles

ABSTRACT

Disclosed here are insoles with one or more regions responsive to maintain a user&#39;s foot in a corrected position in the insole.

RELATED CASES

Priority is claimed herein to U.S. Provisional Patent Application No.61/294716, which was filed on Jan. 13, 2010, and which is incorporatedby reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to insoles with one or more responsiveregions that are constructed to maintain a user's foot in a correctedposition in the insole.

RELATED ART

Severe foot pain is a debilitating experience, which often results in anindividual compensating for the foot pain by shifting the balance ofweight from the foot in pain, to the other foot, which may be in lesspain, or no pain. Compensation in such a manner can result in othersymptoms and/or medical problems such as, for example, pronation,plantar fascitis, heel spurs, and the like.

To ease foot pain, many individuals use removable insoles in theirshoes, which may be made of polymeric materials that provide cushioning.The cushioning properties of the insole provide some pain relief, andallow foot movement within the shoe.

To ease more severe foot pain, resulting from problems with poorposture, misalignment, and the like, custom orthotics may be used. Incontrast to removable insoles, custom orthotics are made of rigidmaterials, and are useful for correcting problems with misalignment offeet, etc., because they force an individual's foot to move into acorrected position, and prevent movement of the foot to the originalposition which caused the problem and foot pain. While effective,orthotics are expensive, heavy, and often uncomfortable.

SUMMARY

The present disclosure is directed, in one embodiment, to an insole. Theinsole comprises a contoured surface selected to maintain a user's footin a corrected position; a footbed comprising a footbed material; and afirst responsive region defined in the footbed, the first responsiveregion comprising a first energy dispersive material, different from thefootbed material; wherein the first energy dispersive material issubstantially flexible in a first configuration such that the user'sfoot can move from the corrected position to an uncorrected position,and substantially rigid in a second configuration, such that upon impactby the user's foot, the first energy dispersive material becomessubstantially rigid and forces the user's foot to move from theuncorrected position to the corrected position.

In another embodiment, the insole comprises a contoured surface selectedto maintain a user's foot in a corrected position; a footbed comprisinga footbed material; a first responsive region defined in the footbed,the first responsive region comprising a first energy dispersivematerial, different from the footbed material; a second responsiveregion defined in the footbed, the second responsive region comprising asecond energy dispersive material different than the footbed materialand the first energy dispersive material; wherein the second materialcomprises a first energy dispersive material that is substantiallyflexible in a first configuration such that the user's foot can movefrom the corrected position to an uncorrected position, andsubstantially rigid in a second configuration, such that upon impact bythe user's foot, the first responsive region becomes substantially rigidand forces the user's foot to move from the uncorrected position to thecorrected position; and wherein the first and second responsive regionsare selected from the group consisting of an arch support, a heel cup, aheel pad, a metatarsal support, and combinations of the foregoing.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages, novel features, and uses of the disclosure will become moreapparent from the following detailed description of non-limitingembodiments of the disclosure when considered in conjunction with theaccompanying drawings, which are schematic and which are not intended tobe drawn to scale. In the figures, each identical or substantiallysimilar component that is illustrated in various figures is typicallyrepresented by a single numeral or notation. For purposes of clarity,not every component is labeled in every figure, nor is every componentof each embodiment of the disclosure shown where illustration is notnecessary to allow those of ordinary skill in the art to understand thedisclosure. In the drawings:

FIG. 1 is a top plan view of one exemplary insole according to thepresent disclosure;

FIG. 1A is a cross-sectional view of the insole of FIG. 1 through line1A-1A;

FIG. 1B is a cross-sectional view of the insole of FIG. 1 through line1B-1B;

FIG. 2 is a top plan view of another exemplary insole according to thepresent disclosure, comprising a heel pad;

FIG. 2A is a cross-sectional view of the insole of FIG. 1 through line2A-2A;

FIG. 2B is a cross-sectional view of the insole of FIG. 1 through line2B-2B;

FIG. 3 is a top plan view of another exemplary insole according to thepresent disclosure, comprising a heel pad and a metatarsal pad;

FIG. 3A is a cross-sectional view of the insole of FIG. 1 through line3A-3A;

FIG. 3B is a cross-sectional view of the insole of FIG. 1 through line3B-3B; and

FIG. 3C is a cross-sectional view of the insole of FIG. 1 through line3C-3C.

DETAILED DESCRIPTION

The present disclosure is directed to relatively lightweight footwearproducts, such as insoles, comprising various degrees of hardness andimpact-resistance. The insoles may comprise one or more responsiveregions that are designed to allow the insole to conform to the shape ofa foot, providing comfort when at rest, and when subjected to a stress,such as when a user is moving (i.e., walking, running, dancing, etc.),to stiffen and to keep the foot in the corrected position. A contouredinsole made at least in part of a responsive material such as a shearthickening foam, may be soft to the touch, but can stiffen on impact tokeep, for example, the heel and arch support of the insole properlyaligned in relation to the foot. That is, the insole is soft enough toconform to the shape of a foot, providing comfort when at rest, butresponsive to keep in the foot properly aligned on the insole and infootwear.

The size, shape and configuration of the insoles can be designed toprovide suitable vibration dampening, impact absorption, frictionreduction, as well as cushioning, which can be varied as desired ornecessary to achieve the desired customized insole characteristics.

Reference will now be made in detail to exemplary embodiments of thedisclosure, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or like parts. The figures,when taken together, illustrate various embodiments of insoles, eachcomprising one or more responsive regions selected to provide varyingdegrees of vibration dampening, impact resistance or absorption,rebound, friction reduction, stabilization and/or cushioning, and thelike, as determined by the needs of a particular user, such as heelpads, metatarsal pads, and the like, based on an evaluation of the needsof a particular individual or of a group of individuals with a commonproblem.

FIGS. 1-1B, when taken together, show one exemplary embodiment of aninsole 5 according to the present disclosure, comprising a foot portion10 (hereinafter “footbed 10”) and two responsive regions defined in thefootbed 10. It should be understood that although the illustratedembodiments comprise two or more responsive regions, as stated above,the present disclosure also encompasses one responsive region. In thepresent embodiment, the insole 5 comprises a responsive heel cup 20(hereinafter “heel cup 20”) and a responsive arch support 30(hereinafter “arch support 30).

Insole 5 may be contoured to conform to the shape of a user's foot, orthe desired corrected position for a user's foot. For example, heel cup20 may be contoured to accommodate the user's heel (not illustrated),and arch support 30 may be contoured to accommodate the instep of theuser's foot (not illustrated), both of which assist in properly locatingor positioning the user's foot on the insole. The shape, size andconfiguration of the insole contours may be predetermined andstandardized based on average foot shapes and sizes, as is common in theindustry or, alternatively, the size, shape and configuration of theinsole may be customized for a particular individual's foot. The insolesdisclosed herein may be manufactured using a variety of techniques andequipment, including those disclosed in commonly owned and co-pendingU.S. patent application Ser. No. 11/644,266, filed on Dec. 23, 2006, thedisclosure of which is incorporated herein by reference in its entirety.

FIGS. 2-2B, when taken together, show another exemplary embodiment of aninsole 5′ according to the present disclosure, comprising a responsiveheel pad 40 (hereinafter “heel pad 40”).

FIGS. 3-3B, when taken together, show another exemplary embodiment of aninsole 5″ according to the present disclosure, comprising a heel pad 40and a metatarsal pad 50 (hereinafter “metatarsal pad 40”).

In any of the foregoing embodiments, the insoles can comprise anymaterials comprising sufficient structural integrity to be formed intopredetermined shapes; sufficient softness and/or pliability to providecomfort against a body; and that are capable of withstanding theenvironment in which it is intended to be used, without substantialdegradation.

Suitable materials for the footbed portion 10 include, but are notlimited to, polymeric materials, including foamed plastics, gelmaterials, such as silicone, elastomers, such as thermoplasticpolyurethane (“TPU”), composite materials, and the like. Examples ofsuitable polymeric materials include, but are not limited to, athermosetting polymeric material, an elastomeric polymeric material,thermoplastic material, including a thermoplastic elastomeric material,and combinations comprising at least one of the foregoing. Some possiblematerials comprise polyurethane, silicone, and/or the like, andcombinations comprising at least one of the foregoing materials.

In any of the foregoing embodiments, the one or more responsive regions(e.g., 20,30,40,50) can comprise any material comprising sufficientstructural integrity to be formed into predetermined shapes; sufficientsoftness and/or pliability to provide comfort against a body, when atrest, and sufficient rigidity to cushion against shock when in use; andthat is capable of withstanding the environment in which it is intendedto be used, without substantial degradation.

Suitable materials for responsive regions include, but are not limitedto, shear thickening or dilatant materials, and the like. As usedherein, the term “shear thickening materials” is meant to cover allcategories of shear thickening materials and combinations of shearthickening materials known to those skilled in the art. Examples ofshear thickening or dilatant materials, include, but are not limited to,shear thickening fluids; shear thickening gels; encapsulated fluids orgels; shear thickening foams; shear thickening solids; shear thickeningfilaments; impregnated fibers (e.g., a fiber or yarn that has absorbed,and/or is coated with, a shear thickening material); impregnated fiberreinforced materials (e.g., a fabric that has absorbed, and/or is coatedwith, a shear thickening material, wherein the impregnated fiberreinforced material includes previously impregnated fibers woventogether to form a fabric); shear thickening composites (e.g., a solidfoamed synthetic polymer with an elastic, and/or an elastomeric matrixand a polymer-based dilatant different from the solid foamed syntheticpolymer, in which the polymer-based dilatant is distributed through thematrix and incorporated therein during manufacture); and a solid, closedcell foam matrix with a polymer-based dilatant, different from thematrix, distributed through the matrix; shear thickening layers (e.g., alayer of material formed from one of, or a combination of, theabove-categories of shear thickening materials).

Shear thickening or dilatant materials have properties that distinguishthem from other materials. For example, when shear thickening materialsare subjected to an increasing rate of shear deformation, they undergoan increase in viscosity and/or rigidity. For example, a shearthickening material may behave like a low viscosity fluid when notsubjected to shear deformation or subjected to a low rate of sheardeformation, but may behave like a highly viscous fluid when subjectedto a high rate of shear deformation. Another shear thickening materialmay behave like a fluid when not subjected to shear deformation orsubjected to a low rate of shear deformation, but may behave like aquasi-solid or solid when subjected to a high rate of shear deformation.Yet another a shear thickening material may behave like a quasi-solid orflexible solid when not subjected to shear deformation or subjected to alow rate of shear deformation, but may behave like a rigid solid whensubjected to a high rate of shear deformation.

Shear thickening foam may be desirable to use for the regions. Suchfoams may be formed by trapping gas bubbles, produced using physical orchemical means, in a shear thickening fluid or gel, after which thematerial may be solidified. The interactions and mechanisms behind theshear thickening behavior of a shear thickening foam may be similar tothose of other shear thickening materials. When the shear thickeningfoam is subjected to the energy of a sudden impact, its rigidity canincrease. Before and after the impact, under normal conditions, theshear thickening foam can be relatively flexible. One suitable shearthickening foam is a polyurethane frothed foam that is commerciallyavailable from Rogers Corporation under the name PORON® XRD, which maybe formed to have a variety of densities and properties. Other shearthickening foams may be used for the responsive regions are availablefrom other manufacturers.

In any of the foregoing embodiments, the responsive regions may bemolded together with the footbed in the same manufacturing operation, orformed separately. If desired, the responsive regions may beencapsulated or covered with another material, and inserted into thefootbed using a variety of techniques, such as, gluing, heat sealing,and the like. Also if desired, various additives and/or active agentsmay be included in the materials, as described in the '266 application.

To produce insoles customized for a particular individual or group ofindividuals, the size, shape and configuration of the responsive regionscan be varied, as can the material and the material properties fromwhich they are formed (e.g., density, durometer, rebound, elasticmodulus, etc.). For example, the responsive regions of an insole cancomprise the same or different materials, and they can comprisematerials with graduated thickness, graduated density, or both. Theconfiguration of the insole 5 can be customized to be responsive to thegait of an individual by using combinations of materials with differentcharacteristics, such as gels, foams, particularly energy dispersivefoams, and other materials, and combinations of the foregoing.

In one exemplary embodiment, in regions of the footbed in whichrelatively low rebound may be desirable, an energy dispersive foam withsuch low rebound characteristics may be used to form the responsiveregions. Regions formed from such a low rebound material can feel softwhen touched, but become hard when impacted. For example, it may bedesirable to have low rebound in the perimeter of the heel cup 20 and/orthe arch support 30. When walking, upon impact of the user's foot to theground, the heel cup and arch support regions 20,30 will harden, therebymaintaining the proper location of the heel and arch within the insole.One suitable material that may be used for such regions is amicrocellular urethane foam available under the product name Poron XRD,from Rogers Corporation. Poron XRD is available with varying levels ofcushioning, impact resistance and rebound characteristics. Comparablematerials are available from other manufacturers.

In another exemplary embodiment, it may be desirable to for certainregions to have relatively high rebound. For example, it may bedesirable to have relatively high rebound in the heel pad 40 and/ormetatarsal pad 50, such that when walking or running, the amount of“bounce” is relatively low. Again, Poron XRD may be a suitable materialfor such an application.

The insoles of the present disclosure can be advantageous because theyare relatively lightweight, simple and inexpensive to manufacture incomparison to other custom orthotics.

Throughout the application, it should be noted that the terms “first,”“second,” and the like herein do not denote any order or importance, butrather are used to distinguish one element from another, and the terms“a” and “an” herein do not denote a limitation of quantity, but ratherdenote the presence of at least one of the referenced items. Similarly,it is noted that the terms “bottom” and “top” are used herein, unlessotherwise noted, merely for convenience of description, and are notlimited to any one position or spatial orientation. In addition, themodifier “about” used in connection with a quantity is inclusive of thestated value and has the meaning dictated by the context (e.g., includesthe degree of error associated with measurement of the particularquantity).

Compounds are described using standard nomenclature. For example, anyposition not substituted by an indicated group is understood to have itsvalency filled by a bond as indicated, or a hydrogen atom A dash (“—”)that is not between two letters or symbols is used to indicate a pointof attachment for a substituent. For example, —CHO is attached throughcarbon of the carbonyl group. Unless defined otherwise herein, allpercentages herein mean weight percent (“wt. %”). Furthermore, allranges disclosed herein are inclusive and combinable (e.g., ranges of“up to about 25 weight percent (wt. %), with about 5 wt. % to about 20wt. % desired, and about 10 wt. % to about 15 wt. % more desired,” areinclusive of the endpoints and all intermediate values of the ranges,e.g., “about 5 wt. % to about 25 wt. %, about 5 wt. % to about 15 wt.%”, etc.). The notation “+/−10% means that the indicated measurement maybe from an amount that is minus 10% to an amount that is plus 10% of thestated value.

Finally, unless defined otherwise, technical and scientific terms usedherein have the same meaning as is commonly understood by one of skillin the art to which this disclosure belongs.

While the disclosure has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended claims.

1. An insole, comprising: a contoured surface selected to maintain auser's foot in a corrected position; a footbed comprising a footbedmaterial; a first responsive region defined in the footbed, the firstresponsive region comprising a first energy dispersive material,different from the footbed material; wherein the first energy dispersivematerial is substantially flexible in a first configuration such thatthe user's foot can move from the corrected position to an uncorrectedposition, and substantially rigid in a second configuration, such thatupon impact by the user's foot, the first energy dispersive materialbecomes substantially rigid and forces the user's foot to move from theuncorrected position to the corrected position.
 2. The insole of claim1, further comprising a second responsive region defined in the footbed,the second responsive region comprising a second energy dispersivematerial different than the footbed material and the first energydispersive material.
 3. The insole of claim 1, wherein the firstresponsive region is selected from the group consisting of an archsupport, a heel cup, a heel pad, a metatarsal support, and combinationsof the foregoing.
 4. The insole of claim 2, wherein the secondresponsive region is selected from the group consisting of an archsupport, a heel cup, a heel pad, a metatarsal support, and combinationsof the foregoing.
 5. The insole of claim 1, wherein the first responsiveregion further comprises a graduated density.
 6. The insole of claim 2,wherein the second responsive region further comprises a graduateddensity.
 7. The insole of claim 1, wherein the first responsive regionfurther comprises a graduated thickness.
 8. The insole of claim 2,wherein the second responsive region further comprises a graduatedthickness.
 9. The insole of claim 1, wherein the first energy dispersivematerial comprises a shear thickening foam.
 10. The insole of claim 2,wherein the second energy dispersive material comprises a shearthickening foam.
 11. The insole of claim 9, wherein the shear thickeningfoam comprises a urethane foam.
 12. The insole of claim 10, wherein theshear thickening foam comprises a urethane foam.
 13. An insole,comprising: a contoured surface selected to maintain a user's foot in acorrected position; a footbed comprising a footbed material; a firstresponsive region defined in the footbed, the first responsive regioncomprising a first energy dispersive material, different from thefootbed material; a second responsive region defined in the footbed, thesecond responsive region comprising a second energy dispersive materialdifferent than the footbed material and the first energy dispersivematerial; wherein the second material comprises a first energydispersive material that is substantially flexible in a firstconfiguration such that the user's foot can move from the correctedposition to an uncorrected position, and substantially rigid in a secondconfiguration, such that upon impact by the user's foot, the firstresponsive region becomes substantially rigid and forces the user's footto move from the uncorrected position to the corrected position; andwherein the first and second responsive regions are selected from thegroup consisting of an arch support, a heel cup, a heel pad, ametatarsal support, and combinations of the foregoing.